Embedded Height Adjustment Mechanism for Double-Wall Building Panels

ABSTRACT

A height adjustment mechanism adjusts the height between first and second walls of a building panel. The walls are typically formed from poured concrete. The mechanism includes a tubular base with an interior threaded surface and extending arms for embedding the base within the first wall when cured. A cap is removable from the base upon curing of the first wall material to expose the base interior threaded surface. A cylindrical torpedo screw is translatable vertically upon rotation of the torpedo screw about its longitudinal axis within the base. The torpedo screw distal end is immersible within the second wall material before curing. In operation, removal of the cap from the base exposes the torpedo screw proximal end such that rotation of the torpedo screw at its proximal end adjusts vertical orientation of the first wall with respect to the second wall.

CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE

This application claims priority benefits from U.S. Provisional Patent Application Ser. No. 61/239,062 filed Sep. 2, 2009, entitled “Embedded Height Adjustment Mechanism For Double-Wall Building Panels”. The '062 provisional application is hereby incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

The present invention relates to the manufacture of multiple-wall building panels. In particular, the present invention relates to a height-adjustment mechanism for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture.

BACKGROUND OF THE INVENTION

In the manufacture of multiple-wall building panels, it is important to control the distance between the walls. In conventional manufacturing techniques, spacers have been used to control the distances between walls during manufacture. Such spacers are fixed in size and do not provide an adjustment function for variably orienting one wall with respect to the other such that the spacing between the walls is controlled. Uncontrolled spacing between the walls can cause structural and functional defects in the resulting double-wall building panel.

SUMMARY OF THE INVENTION

Embodiments of the present technology provide mechanisms and systems for adjusting the height between first and second walls of a multiple-wall building panel.

In certain embodiments, a mechanism for adjusting the height between first and second walls of a multiple-wall building panel, wherein each of said walls are formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, includes: (a) a tubular base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (b) a cap removably attached at a first end to said base and at a second end to said frame interior surface, said cap removable from said base upon curing of said first wall material to expose said base; (c) a cylindrical torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base, said torpedo screw distal end immersible within said second wall material before curing and contacting said frame interior surface, whereby removal of said cap from said base exposes said torpedo screw proximal end such that rotation of said torpedo at its proximal end adjusts vertical orientation of said first wall with respect to said second wall.

In certain embodiments, said slurried material is concrete.

In certain embodiments, said building panel is double-walled.

In certain embodiments, said at least one arm comprises a plurality of arms.

In certain embodiments, said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis. In certain embodiments, said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface.

In certain embodiments, the first end of the cap includes interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base.

In certain embodiments, the second end of the cap is configured to cooperate with a tool for rotating the cap about the tubular base. In certain embodiments, the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench.

In certain embodiments, a method of adjusting the height between first and second walls of a multiple-wall building panel, wherein each of said walls are formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, includes: (a) attaching a cap at one end to a tubular base and at its other end to said frame interior surface; (b) embedding said tubular base within said first wall material, said base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (c) inverting said cured first wall such that said cap extends vertically upwardly from said base; (d) removing said cap from said first wall, thereby exposing said base interior threaded surface; (e) inserting a cylindrical torpedo screw within said base, said torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base; (f) immersing said torpedo screw distal end within said second wall material before curing, said torpedo screw distal end contacting said frame interior surface; (g) rotating said torpedo screw at its proximal end to vertically orient said first wall with respect to said second wall.

In certain embodiments, said slurried material is concrete.

In certain embodiments, said building panel is double-walled.

In certain embodiments, said at least one arm comprises a plurality of arms.

In certain embodiments, said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis. In certain embodiments, said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface.

In certain embodiments, the cap includes a first end comprising interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base.

In certain embodiments, the cap includes a second end configured to cooperate with a tool for rotating the cap about the tubular base. In certain embodiments, the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench.

DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of a height adjustment mechanism for use when fabricating double-wall building panels used in accordance with embodiments of the present technology.

FIG. 2 depicts a side-sectional view of the height adjustment mechanism of FIG. 1.

FIG. 3 depicts a top view of a tubular base used in connection with the height adjustment mechanism of FIG. 1.

FIG. 4 depicts a side view of a cylindrical torpedo screw used in connection with the height adjustment mechanism of FIG. 1.

FIG. 5 depicts a top view of the cylindrical torpedo screw of FIG. 4.

FIG. 6 depicts a side view of the tubular base of FIG. 3

FIG. 7 depicts a side-sectional view of a cap used in connection with the height adjustment mechanism of FIG. 1.

FIG. 8 depicts a top view of the cap of FIG. 7.

FIGS. 9-15 depict steps involved in a technique for adjusting the height between first and second walls of a multiple-wall panel used in accordance with an embodiment of the present technology.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S)

The present invention relates to the manufacture of multiple-wall building panels. In particular, the present invention relates to a height-adjustment mechanism for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture. In the figures, like elements have like identifiers.

FIG. 1 depicts a perspective view of a height adjustment mechanism 100 for use when fabricating double-wall building panels used in accordance with embodiments of the present technology. FIG. 2 depicts a side-sectional view of the height adjustment mechanism 100, which includes tubular base 102, cap 104 and cylindrical torpedo screw 106.

Tubular base 102 includes an interior threaded surface 108, an exterior surface 110, and arms 112 that extend from exterior surface 110. Tubular base 102 is also depicted in FIGS. 3 and 6. In certain embodiments, tubular base can include a single arm rather than two arms. While arms 112 are linear elements, in certain embodiments, an arm can be non-linear. In certain embodiments, each arm 112 can have a length of about 6 inches, tubular base 102 can comprise a 0.75 coil thread insert, and arms 112 can be attached to exterior surface 110 of tubular base 102 about 0.5 inches from the end of tubular base 102 that does not receive cap 104.

Cylindrical torpedo screw 106 includes a distal end 114, a proximal end 116, a threaded exterior 118 therebetween, and a fitting 120 disposed at the proximal end 116. Threaded exterior 118 of torpedo screw 106 is configured to be received by interior threaded surface 108 of tubular base 102 such that torpedo screw 106 is translatable vertically relative to tubular base 102 upon rotation of torpedo screw 106 about its longitudinal axis within tubular base 102. Fitting 120 is configured to cooperate with a tool for rotating torpedo screw 106 about its longitudinal axis. For example, in certain embodiments, fitting 120 can be configured to cooperate with an interior surface of a socket wrench 1302, as depicted in FIGS. 13-14. Cylindrical torpedo screw 106 is also depicted in FIGS. 4 and 5. In certain embodiments, torpedo screw 106 can have an exterior surface diameter of about 0.75 inches and a total length of about 8 inches, 10 inches or 12 inches, and fitting 120 can be a square with 0.5 inch sides.

Cap 104 includes a first end 122 and a second end 124 opposite the first end 122. First end 122 is configured to be removably attached to tubular base 102. For example, first end 122 can include interior threads 126 configured to receive exterior surface 110 of tubular base 102 such that cap 104 is translatable vertically relative to tubular base 102 upon rotation of cap 104 about tubular base 102. Second end 124 is configured to cooperate with a tool for rotating cap 104 about tubular base 102. For example, in certain embodiments, second end 124 can have an interior surface 128 configured to receive an exterior surface of a cone wrench 1202 in order to rotate cap 104 about tubular base 102, as depicted in FIG. 12. Cap 104 is removable from tubular base 102 to expose proximal end 116 of torpedo screw 106 such that fitting 120 can be rotated. Cap 104 is also depicted in FIGS. 7 and 8. In certain embodiments, cap 104 comprises a 1.5 inch height plastic cone with 0.75 inch interior coil threads at first end 122 to a 0.5 inch depth configured to receive tubular base 102, and a 1 inch depth interior opening at the second end 124 configured to receive an exterior portion of a cone wrench.

As discussed further in connection with FIGS. 9-15, tubular base 102, cap 104, and proximal end 116 of torpedo screw 106 (disposed within cap 104 and tubular base 102) can be immersed in a first wall formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame. After the first wall has cured, distal end 114 of torpedo screw 106 can be immersed in a second wall formed of a slurried material that has been poured into a horizontally disposed frame to cure, such that the first wall is substantially parallel to the second wall and the two walls are coterminous. Cap 104 can then be removed, thereby exposing fitting 120 of torpedo screw 106. Separation distance between the first and second wall can then be adjusted by rotating torpedo screw 106 about its longitudinal axis within tubular base 102 such that torpedo screw 106 translates vertically relative to tubular base 102. Once a desired separation distance is achieved, the second wall can be allowed to cure, for example, in a kiln. After curing, torpedo screw can be removed completely and the separation distance between the walls can be maintained by other spacer elements that were also immersed in the first and second walls.

FIGS. 9-15 depict steps involved in such a technique for adjusting the height between first and second walls of a multiple-wall panel used in accordance with an embodiment of the present technology.

FIG. 9 depicts a first wall 904 formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame with horizontal interior surface 902. In certain embodiments, first wall 904 can have a thickness of 2 and ⅜ inches. The end of height adjustment mechanism 100 with tubular base 102, cap 104, and proximal end 116 of torpedo screw 106 (disposed within cap 104 and tubular base 102) is immersed in first wall 904 such that cap 104 contacts horizontal interior surface 902. In certain embodiments, cap 104 can be glued to horizontal interior surface 902. Truss girders 906 are also immersed in the first wall 904, but do not contact horizontal interior surface 902. In certain embodiments, truss girders 906 can be held in place using wire strands or supported using plastic chairs, for example. In certain embodiments, any number of height adjustment mechanisms 100 and truss girders 906 can be used depending on the size and shape of a wall. Once the height adjustment mechanism 100 and truss girders 906 are in place, the slurried material of first wall 904 is allowed to cure, for example, in a kiln.

FIG. 10 depicts a second wall 1004 formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame with horizontal interior surface 1002. In certain embodiments, second wall 1004 can have a thickness of 2 and ⅜ inches. First wall 904, which has been removed from its frame and inverted, for example, using a vacuum turning device, is oriented over second wall 1004 such that first wall 904 and second wall 1004 are substantially parallel and the surfaces areas of both walls are coterminous.

Once properly aligned, as depicted in FIG. 11, first wall 904 is lowered toward second wall 1004 until distal end 114 of torpedo screw 106 is immersed in second wall 1004 such that distal end 114 of torpedo screw 106 contacts horizontal interior surface 1002 of the frame that the second wall 1004 is provided in. Truss girders 906 are also immersed in the second wall 1004, but do not contact horizontal interior surface 1002.

At this stage, as depicted in FIG. 12, cap 104 can be removed, for example, using a cone wrench 1202. That is, an exterior portion 1204 of cone wrench 1202 configured to cooperate with interior surface 128 of second end 124 of cap 104 can be inserted into interior surface 128 of second end 124 of cap 104 and rotated, thereby unscrewing interior threads 126 of first end 122 of cap 104 from exterior surface 110 of tubular base 102.

Once cap 104 is removed, as depicted in FIG. 13, proximal end 116 of torpedo screw 106 is exposed such that fitting 120 can be rotated. That is, an interior portion 1402 of socket wrench 1302 configured to cooperate with fitting 120 of torpedo screw 106 can be fitted over fitting 120 and rotated about its longitudinal axis within tubular base 102, thereby translating torpedo screw 106 vertically relative to tubular base 102. This can allow separation distance x to be increased by rotating torpedo screw 106 in a first direction about its longitudinal axis within base 102. This can also allow separation distance x to be decreased by rotating torpedo screw 106 in a second direction about its longitudinal axis within base 102 that is opposite the first direction. Thus, separation distance x between first wall 906 and second wall 1006 can be manipulated until a desired double panel wall thickness is achieved. Once the desired separation distance x is achieved, second wall 1006 can be allowed to cure, for example, in a kiln. Once second wall 1006 is cured, torpedo screw 106 can be removed completely by unscrewing torpedo screw 106 from interior surface 108 of tubular base 102. FIG. 14 depicts torpedo screw 106 being removed from tubular base 102 in this manner.

Once torpedo screw 106 is removed, as depicted in FIG. 15, the separation distance x between first wall 904 and second wall 1004 can be maintained by truss girders 906. All that remains of the height adjustment mechanism 100 within the double wall panel is tubular base 102 with arm 112.

In certain embodiments, operating the mechanisms and/or applying the methods described herein can provide for improved height-adjustment for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture.

While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings. 

1. A mechanism for adjusting the height between first and second walls of a multiple-wall building panel, each of said walls formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, the mechanism comprising: (a) a tubular base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (b) a cap removably attached at a first end to said base and at a second end to said frame interior surface, said cap removable from said base upon curing of said first wall material to expose said base; (c) a cylindrical torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base, said torpedo screw distal end immersible within said second wall material before curing and contacting said frame interior surface, whereby removal of said cap from said base exposes said torpedo screw proximal end such that rotation of said torpedo at its proximal end adjusts vertical orientation of said first wall with respect to said second wall.
 2. The height adjustment mechanism of claim 1, wherein said slurried material is concrete.
 3. The height adjustment mechanism of claim 1, wherein said building panel is double-walled.
 4. The height adjustment mechanism of claim 1, wherein said at least one arm comprises a plurality of arms.
 5. The height adjustment mechanism of claim 1, wherein said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis.
 6. The height adjustment mechanism of claim 5, wherein said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface.
 7. The height adjustment mechanism of claim 1, wherein the first end of the cap includes interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base.
 8. The height adjustment mechanism of claim 1, wherein the second end of the cap is configured to cooperate with a tool for rotating the cap about the tubular base.
 9. The height adjustment mechanism of claim 8, wherein the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench.
 10. A method of adjusting the height between first and second walls of a multiple-wall building panel, each of said walls formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, the method comprising: (a) attaching a cap at one end to a tubular base and at its other end to said frame interior surface; (b) embedding said tubular base within said first wall material, said base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (c) inverting said cured first wall such that said cap extends vertically upwardly from said base; (d) removing said cap from said first wall, thereby exposing said base interior threaded surface; (e) inserting a cylindrical torpedo screw within said base, said torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base; (f) immersing said torpedo screw distal end within said second wall material before curing, said torpedo screw distal end contacting said frame interior surface; (g) rotating said torpedo screw at its proximal end to vertically orient said first wall with respect to said second wall.
 11. The method of claim 10, wherein said slurried material is concrete.
 12. The method of claim 10, wherein said building panel is double-walled.
 13. The method of claim 10, wherein said at least one arm comprises a plurality of arms.
 14. The method of claim 10, wherein said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis.
 15. The method of claim 14, wherein said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface.
 16. The method of claim 10, wherein the cap includes a first end comprising interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base.
 17. The method of claim 16, wherein the cap includes a second end configured to cooperate with a tool for rotating the cap about the tubular base.
 18. The method of claim 17, wherein the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench. 